基于相场模型的3D打印设计-优化-仿真一体化研究

ON THE INTEGRATED 3D PRINTING RESEARCH FOR DESIGN,OPTIMIZATION AND SIMULATION WITHIN PHASE FIELD FRAMEWORK

制件设计(“数字化”),性能优化(“优化化”),工艺仿真(“仿真化”)是3D打印过程的三个重要模块.“数字化”是指将设计图纸/预加工实物,通过图像/视频/扫描等处理手段,转化为可编辑的数字化制件.“优化化”是指在数字化的制件上施加力学,热学等物理场约束,提高制件性能.“仿真化”是指根据优化化的制件模拟真实制造场景的物理工况,进行加工过程中的物理化学变化的数字仿真和孪生建模仿真.本研究旨在介绍基于相场模型框架下的特定工艺3D打印设计-优化-仿真建模与算法研究.在“数字化”模块中,我们将针对计算机辅助设计常见的数据类型,介绍相应的三维重构模型,修补模型以及轻量化支撑结构设计模型.在“优化化”模块中,我们将介绍系列多尺度,多物理场,多材料耦合的拓扑优化问题及相应的求解方法.在“仿真化”模块中,结合3D打印参数和工艺,我们介绍宏观(相变)-微观(晶界)尺度耦合的熔融沉积成型(FDM)工艺仿真方法,以及基于激光-热-流-固等物理场耦合理论的选择性激光熔化(SLM)工艺的仿真方法.基于相场模型框架下的设计-优化-仿真研究方法将有助于缩短产品开发周期,提高设计效率,为实现3D打印制件质量溯源和根因分析提供理论依据和算法支撑.

Component design("digitalization"),performance optimization("optimization"),and Component design("digitalization"),performance optimization("optimization"),an process simulation("simulation")are three critical modules in the 3D printing process."Digitalization"refers to the transformation of design drawings or pre-processed physical objects into editable digital components through means such as images,videos,and scanning processes."Optimization"involves the application of constraints from physical fields such as mechanics and thermodynamics to enhance the performance of digital components."Simulation"entails the digital simulation and twin modeling of physicochemical changes during the manufacturing process,based on the optimized components,to emulate real-world physical conditions.This research aims to introduce integrated modeling and algorithmic studies in design,optimization,and simulation within the phase field framework.In the"digitalization"module,we will present three-dimensional reconstruction models,repair models,and lightweight support structure design models that correspond to common data types in computer-aided design.In the"optimization"module,we will introduce a series of multi-scale,multi-physical field,and multi-material coupled topology optimization problems and their corresponding solutions.In the"simulation"module,we will discuss macroscopic(phase transition)to microscopic(grain boundary)scale coupling theories and the physical field couplings such as laser-thermal-flow-solid,in addition to simulating methods for processes like Fused Deposition Modeling(FDM)and Selective Laser Melting(SLM),integrating 3D printing parameters and techniques.The integrated research approach to design,optimization,and simulation based on the phase field model framework aims to shorten the product development cycle,enhance design efficiency,and provide a theoretical basis and algorithmic support for quality traceability and root cause analysis of 3D printed components.